Apparatus for mounting a solar panel and method and apparatus for forming the mounting apparatus

ABSTRACT

A support member for a solar panel is provided comprising a base member having first and second surfaces and first and second sides, the first surface defining a recess configured to receive the solar panel. The first side of the support member defines a first flange extending therefrom that is flush with the first surface of the base member and the second side of the support member defines a second flange extending therefrom that is flush with the second surface of the base member.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to solar panel support apparatuses andmethods and apparatuses for constructing the same.

2. Description of Related Art

The use of reusable energy sources is becoming increasingly moreimportant to national and local governments due to concerns over globalwarming; the eventual exhaustion of certain conventional energysupplies, such as oil, natural gas and coal; and the increasing cost forsuch energy supplies. One reusable energy source is solar energy orsunlight, which is captured and converted into electricity using solarenergy cells or panels of such cells, as is well known in the art. Whilesolar energy is an abundant energy source and the technology involved incapturing and converting the solar energy into electricity relativelywell developed, solar energy remains relatively underused due to, amongother factors, the need to have large, unobstructed areas to positionthe panels and the adverse aesthetic impact of such panels.

One proposal to increase the usage of solar panels is to locate thepanels on roof tops of residential and/or industrial structures.However, there remain aesthetic concerns with locating conventionalsolar panels on a roof top due to the height such panels extend abovethe roof line. In addition, the weight of the solar panels and supportstructure on the roof top and the structural ability of the panels andsupport structure to withstand high winds and other ambient conditionsis also a concern. Finally, the efficiency of a solar panel decreases asthe temperature of the panel increases, so an important objective indeveloping a solar energy system is to ensure that heat does not buildup around the panels. Thus, there remains a need for a support structurefor a solar panel that can be used to position one or more panelsinconspicuously on a roof top, that is light enough not to adverselyaffect the structural integrity of the roof top but that still hassufficient mechanical strength and weight to withstand high winds andother ambient conditions, and that allows for air to circulate aroundthe solar panel to reduce overheating.

SUMMARY OF THE INVENTION

Embodiments of the present invention provide improved apparatus formounting a solar panel and method and apparatus for forming the mountingapparatus. More particularly, embodiments of the present inventionprovide a support member for a solar panel comprising a base memberhaving first and second surfaces and first and second sides, wherein thefirst surface defines a recess configured to receive a solar panel. Inone embodiment, the support member is formed of polymer concrete. Inanother embodiment, the recess is configured such that the solar panelcan be positioned within the recess with relatively insubstantial gapsbetween the sides of the recess and the sides of the panel and with thefront of the panel being substantially flush with the first surface ofthe support member. The first surface of the base member defines atleast one aperture within the recess to provide space for air tocirculate and to reduce the weight of the support member. In oneembodiment, the at least one aperture comprises at least one slot. Inanother embodiment, the at least one aperture comprises at least onecircular opening.

In another embodiment of the present invention, the first surface of thebase member defines a plurality of raised members within the recess thatare structured to engage the solar panel and to provide space betweenthe first surface of the base member and the solar panel. In oneembodiment, the raised members within the recess comprise an elongaterib.

In yet another embodiment, the first side of the base member defines afirst flange extending therefrom that is flush with the first surface ofthe base member and the second side defines a second flange extendingtherefrom that is flush with the second surface of the base member. Inone embodiment, the first flange defines a first lip at the distal endof the first flange and a groove between the first lip and the firstside of the base member and the second flange defines a second lip atthe distal end of the second flange and a groove between the lip and thesecond side of the base member.

In still another embodiment of the invention, the base member defines asecond recess configured to receive a junction box, wherein the secondrecess defines an aperture configured to accommodate the wiring of thesolar panel and to provide space for air to circulate about the back ofthe solar panel.

Embodiments of the invention also provide a solar panel array,comprising at least two solar panels and at least two support members inaccordance with the present invention. Each of the support memberscomprises a base member having first and second surfaces and first andsecond sides. The first surface of each of the base members defines arecess configured to receive one of the solar panels. In one embodiment,the first surface of each of the base members defines at least oneaperture within the recess to enable air to circulate about the back ofthe corresponding solar panel and to reduce the weight of the supportmember. The first side of each base member defines a first flangeextending therefrom that is flush with the first surface of the basemember, the second side of each base member defines a second flangeextending therefrom that is flush with the second surface of the basemembers. In one embodiment, the first flange of each base member definesa first lip at the distal end of the first flange and a groove betweenthe first lip and the first side of the base member and the secondflange of each base member defines a second lip at the distal end of thesecond flange and a groove between the second lip and the second side ofthe base member. At least two support members are positioned adjacent toone another such that the first flange of one of the at least twosupport members overlaps said second flange of the adjacent one of saidat least two support members.

The invention also provides a method of forming a solar panel supportmember. In one embodiment, the method includes providing a first molddefining a plurality of protuberances, encasing the first mold with aform, and filling the first mold with liquid polymeric material andaggregate. Thereafter, a second mold is provided and positioned on thefirst mold within the form and the first and second molds are urgedtogether. Finally the polymeric material is cured to form a supportmember in accordance with the present invention and the support memberis removed from the first and second molds.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1 is a perspective view illustrating a solar panel support,according to one embodiment of the present invention;

FIG. 2 is front view illustrating the solar panel support of FIG. 1;

FIG. 3 is a side view illustrating the solar panel support of FIG. 1;

FIG. 4 is a rear view illustrating the solar panel support of FIG. 1;and

FIG. 5 is a sectional view illustrating the solar panel support of FIG.4 along the lines 5-5;

FIG. 6 is a sectional view illustrating the solar panel support of FIG.5 along the lines 6-6;

FIG. 7 is a sectional view illustrating the solar panel support of FIG.4 along the lines 7-7;

FIG. 8A is a perspective view illustrating a first portion of a mold forconstructing the solar panel support of FIG. 1, according to oneembodiment of the present invention;

FIG. 8B is a side view illustrating the first portion of the mold inFIG. 8A;

FIG. 8C is a top view illustrating the first portion of the mold in FIG.8A;

FIG. 8D is a sectional view illustrating the first portion of the moldin FIG. 8C along the lines 8D-8D;

FIG. 8E is a sectional view illustrating the first portion of the moldin FIG. 8C along the lines 8E-8E;

FIG. 8F is a sectional view illustrating the first portion of the moldin FIG. 8C along the lines 8F-8F;

FIG. 9A is a perspective view illustrating a second portion of a moldfor constructing the solar panel support of FIG. 1, according to oneembodiment of the present invention;

FIG. 9B is a side view illustrating the second portion of the mold inFIG. 9A;

FIG. 9C is a top view illustrating the second portion of the mold inFIG. 9A;

FIG. 9D is a sectional view illustrating the second portion of the moldin FIG. 9C along the lines 9D-9D;

FIG. 9E is a sectional view illustrating the second portion of the moldin FIG. 9C along the lines 9E-9E;

FIG. 9F is a sectional view illustrating the second portion of the moldin FIG. 9C along the lines 9F-9F;

FIG. 10 is a perspective view illustrating a solar panel support and asolar panel, according to one embodiment of the present invention; and

FIG. 11 is a perspective view illustrating a plurality of solar panelsupports and solar panels installed on a roof top, according to oneembodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention now will be described more fullyhereinafter with reference to the accompanying drawings, in which some,but not all, embodiments of the inventions are shown. Indeed, theinvention may be embodied in many different forms and should not beconstrued as limited to the embodiments set forth herein; rather, theseembodiments are provided so that this disclosure will satisfy applicablelegal requirements. Like numbers refer to like elements throughout.

Referring to the drawings and, in particular, FIGS. 1-7, there isillustrated a solar panel support member 10, according to one embodimentof the present invention. The dimensions of the support member 10illustrated in FIGS. 1-4 are provided for purposes of example only andmay be modified depending on the dimensions and configuration of thesolar panel to be supported. As illustrated in FIGS. 1, 2 and 4, thesupport member 10 includes a base member 11 having first and secondsurfaces 14 a, b and a first pair of lateral sides 16 a, b and a secondpair of lateral sides 18 a, b. The support member 10 can be formed of avariety of materials including metal, wood, plastic or cementitiousmaterials. In one preferred embodiment, the support member 10 is formedof a polymer concrete.

As illustrated in FIGS. 1 and 2, the front surface 14 a of the supportmember 10 defines a recess 12 structured to receive a solar panel 20, asillustrated in FIG. 10. More particularly, the width, length and depthof the recess 12 is such that the solar panel 20 can be positionedwithin the recess with relatively insubstantial gaps between the sidesof the recess and the sides of the panel and with the front of the panelbeing substantially flush with the front surface 14 a of the supportmember 10.

The support member 10 defines a plurality of apertures 22 therethroughwithin the recess 12. The apertures 22 can include slots 24 and circularapertures 26 that advantageously allow for circulation of air around theexposed areas on back of the solar panel 20 and reduce the weight of thesupport member 10 by removing excess material. The remaining materialbetween the apertures 22 defines a framework that provides thestructural strength to the support member 10 to support the solar panel20. The slots 24 and circular apertures 26 are shown for illustrationpurposes only. The dimensions and configurations of the apertures 22 canvary depending on, without limitation, the size and shape of the supportmember 10, the excess material that needs to be removed, and thestructural requirements of the support member and solar panel 14 asdetermined by the weight of the support member and solar panel, theanticipated wind forces and other ambient conditions, and theload-bearing ability of the roof or other underlying structure to whichthe support member will be anchored. According to another embodiment ofthe present invention (not shown), the support member defines ahoney-comb configuration or pattern within the recess 12.

In one embodiment of the present invention, as illustrated in FIG. 2,the support member 10 includes a second recess 28 that is structured toreceive or accommodate a junction box (not shown) on the back of thesolar panel 20. An aperture 30 may be provided through the supportmember 10 within the second recess 28 to accommodate the wiring of thesolar panel 20 and to allow air to circulate around the exposed surfaceof the junction box. In other embodiments, the wiring of the solar panel20 can be configured substantially within the plane of the back surfaceof the solar panel, in such case, the second recess 28 and aperture 30may be omitted.

As illustrated in FIGS. 1 and 2, the support member 10 includes aplurality of raised members 40 on the framework within the recess 12that contact the back of the solar panel 20 and create a further gapbetween the support member and the back of the panel, substantiallyincreasing the exposed area of the back of the panel so that air cancirculate around a greater portion of the back of the panel. Theconfiguration of the raised members 40 can vary. In the embodimentillustrated in FIG. 2, the raised members 40 are configured as elongateribs. In other embodiments (not shown), the raised members 40 can haveother configurations, including, without limitation, circular,elliptical, square, or rectangular configurations.

As illustrated in FIGS. 1 and 3, the lateral sides 16 a, b of thesupport member define a pair of opposed first and second flanges 32 a,b. The first flange 32 a extends from the first lateral side 16 a and isflush with the first surface 14 a. The second flange 32 b extends fromthe second lateral side 16 b and is flush with the second surface 14 b.As illustrated in FIGS. 1 and 3, each flange 32 a, b defines a lip 33 atthe distal end of the flange and a groove 35 between the lip and thecorresponding lateral side 16 a, b. As illustrated in FIG. 11, aplurality of the support members 10 can be positioned on a roof topadjacent one another wherein the first flange 32 a of one support member10 overlaps and secures the second flange 32 b of an adjacent supportmember to thereby interconnect the support members and secure them tothe roof top. The first and second flanges 32 a, b are secured togetherby the lip 33 of the first flange 32 a being inserted into the groove 35of the second flange 32 b and by the lip 33 of the second flange beinginserted into the groove 35 of the first flange. The support members 10are preferably positioned on a roof top so that the second surface 14 bof each support member is substantially flush with, and parallel to, theplane defined by the roof top so that the support members and solarpanels 14 are relatively inconspicuous and aesthetically blend into thecovering of the roof top. In other embodiments, the flanges 32 a, b canbe omitted and the support member 10 secured to the roof top withfasteners via apertures 36 (for example, as shown in FIGS. 2 and 4),which can also be used to mount the support member and solar panel on avertical wall.

Referring to FIGS. 8 a-8 f and 9 a-9 f, there is illustrated a two-partmold 34 a, b that can be used to form the support member 10 usingcementitious, metal or plastic materials, such as polymer concrete. Ascan be seen, the individual parts of the mold have protuberances andrecesses corresponding to the apertures 22 and recesses 12, 28 of thesupport member 10. The support member 10 is formed by positioning thefirst part 34 a of the mold within an external form, such as a woodform. The cementitious, metal or plastic material is pored into thefirst part of the mold 34 a to the height of the protuberances and thenthe second part 34 b of the mold is placed on top of the material andthe first part of the mold. The two parts of the mold 34 a, b are thenurged together to form the support member and, thereafter, the materialis allowed to cool or cure. The second part of the mold 34 b is thenremoved and the support member removed from the first part of the mold34 a. If necessary, apertures 36 can be formed in the support member 10by drilling.

The solar panel 20 is secured within the recess 12 of the support member10 using suitable fasteners and/or adhesives, such as silicone caulk.The support members 10 can then be mounted to the roof top either byoverlapping the opposed flanges 32 a, b extending from the lateral sides16 a, b of the support member or using fasteners.

Many modifications and other embodiments of the invention set forthherein will come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the invention is not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation.

1. A support member for a solar panel, comprising: a base member havingfirst and second surfaces and first and second sides, said first surfacedefining a recess configured to receive the solar panel, said basemember being formed of polymer concrete.
 2. A support member accordingto claim 1 wherein said recess is configured such that the solar panelcan be positioned within said recess with relatively insubstantial gapsbetween the sides of said recess and the sides of the solar panel andwith the front of the solar panel being substantially flush with saidfirst surface of said base member.
 3. A support member according toclaim 1 wherein said first surface defines at least one aperture withinsaid recess structured to provide space for air to circulate about theback of the solar panel and to reduce the weight of said base member. 4.A support member according to claim 1 wherein said at least one aperturecomprises at least one slot.
 5. A support member according to claim 1wherein said at least one aperture comprises at least one circularopening.
 6. A support member according to claim 1 wherein said firstsurface of said base member defines a plurality of raised members withinsaid recess that are structured to engage the solar panel and to providespace between said first surface of said base member and the solarpanel.
 7. A support member according to claim 6 wherein at least one ofsaid plurality of raised members comprises at least one elongate rib. 8.A support member according to claim 1 wherein said first side of saidbase member defines a first flange extending therefrom that is flushwith said first surface of said base member and wherein said second sideof said base member defines a second flange extending therefrom that isflush with said second surface of said base member.
 9. A support memberaccording to claim 8 wherein said first flange defines a first lip atthe distal end of said first flange and a groove between said first lipand said first side of said base member and said second flange defines asecond lip at the distal end of said second flange and a groove betweensaid second lip and said second side of said base member.
 10. A supportmember according to claim 1 wherein said first surface of said basemember defines a second recess configured to receive a junction box,said second recess defining an aperture configured to receive theelectrical wiring of the solar panel and to provide space for air tocirculate about the back of the solar panel.
 11. A solar panel array,comprising: at least two solar panels; at least two support members,each of said at least two support members comprising a base memberhaving first and second surfaces and first and second sides, said firstsurface of each of said base members defining a recess configured toreceive one of said at least two solar panels, said first side of eachof said base members defining a first flange extending therefrom that isflush with said first surface of the corresponding one of said basemembers, said second side of each of said base members defining a secondflange extending therefrom that is flush with said second surface of thecorresponding one of said base members; and wherein said at least twosupport members are positioned adjacent to one another such that saidfirst flange of one of said at least two support members overlaps saidsecond flange of the adjacent one of said at least two support members.12. A solar array according to claim 11 wherein said first surface ofeach of said base members defines a plurality of raised members withinsaid recess that are structured to engage the back of said one of saidat least two solar panels and to provide space between said firstsurface of each of said base members and the back of said one of said atleast two solar panels.
 13. A solar array according to claim 12 whereinat least one of said plurality of raised members comprises at least oneelongate rib.
 14. A solar array according to claim 11 wherein said firstflange of each of said base members defines a first lip at the distalend of said first flange and a groove between said first lip and saidfirst side of the corresponding one of said base members and said secondflange of each of said base members defines a second lip at the distalend of said second flange and a groove between said second lip and saidsecond side of the corresponding one of said base members.
 15. A solararray according to claim 11 where in each of said at least two supportmembers is formed of polymer concrete.
 16. A solar array according toclaim 11 wherein said recess of each of said base members is configuredsuch that said one of said at least two solar panels can be positionedwithin said recess with relatively insubstantial gaps between the sidesof said recess and the sides of said one of said at least two solarpanels and with the front of said one of said at least two solar panelsbeing substantially flush with said first surface of the correspondingone of said base members.
 17. A solar array according to claim 17wherein said first surface of each of said base members defining atleast one aperture within said recess to enable air to circulate aboutthe back of said one of said at least two solar panels and to reduce theweight of the corresponding one of said at least two support members.18. A solar array according to claim 17 wherein said at least oneaperture comprises at least one slot.
 19. A solar array according toclaim 17 wherein said at least one aperture comprises at least onecircular opening.
 20. A solar array according to claim 11 furthercomprising at least two junction boxes and wherein said first surface ofeach of said base members defines a second recess configured to receiveone of said at least two junction boxes, said second recess defining anaperture configured to receive the electrical wiring of said one of saidat least two solar panels and to provide space for air to circulateabout the back of said one of said at least two solar panels.
 21. Amethod of forming a support member for a solar panel, comprising:providing a first mold defining a plurality of protuberances; encasingthe first mold with a form; filling the first mold with liquid polymericmaterial and aggregate; positioning a second mold on the first moldwithin the form; urging the first and second molds together; curing thepolymeric material to form a support member, the support membercomprising a base member having first and second surfaces and first andsecond sides, said first surface of said base member defining a recessconfigured to receive a solar panel; and removing the support memberfrom the first and second molds.